US20180152077A1 - High-speed hall sensor-less three-phase vacuum cleaner motor - Google Patents

High-speed hall sensor-less three-phase vacuum cleaner motor Download PDF

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Publication number
US20180152077A1
US20180152077A1 US15/575,985 US201515575985A US2018152077A1 US 20180152077 A1 US20180152077 A1 US 20180152077A1 US 201515575985 A US201515575985 A US 201515575985A US 2018152077 A1 US2018152077 A1 US 2018152077A1
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US
United States
Prior art keywords
hall sensor
less
end cap
controller
vacuum cleaner
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US15/575,985
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English (en)
Inventor
Zugen Ni
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kingclean Electric Co Ltd
Original Assignee
Kingclean Electric Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kingclean Electric Co Ltd filed Critical Kingclean Electric Co Ltd
Assigned to KINGCLEAN ELECTRIC CO., LTD. reassignment KINGCLEAN ELECTRIC CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NI, ZUGEN
Publication of US20180152077A1 publication Critical patent/US20180152077A1/en
Abandoned legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/02—Arrangements for cooling or ventilating by ambient air flowing through the machine
    • H02K9/04—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
    • H02K9/06—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L5/00—Structural features of suction cleaners
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
    • A47L9/28—Installation of the electric equipment, e.g. adaptation or attachment to the suction cleaner; Controlling suction cleaners by electric means
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
    • A47L9/28—Installation of the electric equipment, e.g. adaptation or attachment to the suction cleaner; Controlling suction cleaners by electric means
    • A47L9/2805—Parameters or conditions being sensed
    • A47L9/2831—Motor parameters, e.g. motor load or speed
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
    • A47L9/28—Installation of the electric equipment, e.g. adaptation or attachment to the suction cleaner; Controlling suction cleaners by electric means
    • A47L9/2889—Safety or protection devices or systems, e.g. for prevention of motor over-heating or for protection of the user
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K29/00—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/14—Electronic commutators
    • H02P6/16—Circuit arrangements for detecting position
    • H02P6/18—Circuit arrangements for detecting position without separate position detecting elements
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/14—Electronic commutators
    • H02P6/16—Circuit arrangements for detecting position
    • H02P6/18—Circuit arrangements for detecting position without separate position detecting elements
    • H02P6/182—Circuit arrangements for detecting position without separate position detecting elements using back-emf in windings

Definitions

  • the present application relates to a high-speed Hall sensor-less three-phase vacuum cleaner motor.
  • a conventional vacuum cleaner motor generally includes a series-excited vacuum cleaner motor and a small direct-current vacuum cleaner motor.
  • a brush motor with a rotational speed of 20000-40000 rotations per minute is usually adopted.
  • the brush motor has a large volume, a poor performance, a limited application range and a short service life, and is inconvenient to carry.
  • a brushless motor is adopted, high-level hardware and circuit control are required, and mostly, a Hall element is adopted to detect a magnetic position to realize magnetic field oriented control.
  • the Hall element in use often has the following problems: 1. the price is high and thus is difficult to be accepted by customers; 2.
  • the Hall element is hard to install, and if being improperly installed, the Hall element is apt to be damaged to result in breakdown or poor start; 3. it is easy to introduce interference and decreased reliability because of an increase in interfaces and connecting lines between the motor and a control system; 4. it has severe service environment requirements, since the motor is vulnerable to damage in the environment with a high temperature, high humidity, serious vibration, dust or harmful chemicals; 5. it may increase the volume of the motor and demands a bigger motor space. Because of the above disadvantages, a Hall sensor-less structure motor is adopted to replace a Hall-structure motor. However, due to the difficulty in Hall sensor-less technology, the Hall sensor-less motor in the current market has a low rotational speed, which is usually lower than 40000 rotations per minute. And moreover, the Hall sensor-less motor has a large commutation number, a large commutation loss and a complex stator structure, which is not convenient to wind.
  • An object of the present application is to provide a high-speed Hall sensor-less three-phase vacuum cleaner motor to achieve a Hall sensor-less structure motor with a rotational speed greater than 80000 rotations per minute. And a super-high dust collection performance of the vacuum cleaner is achieved by applying the motor.
  • a high-speed Hall sensor-less three-phase vacuum cleaner motor includes a Hall sensor-less circuit cooled by wind outputted by the motor, and a rotational speed of the motor controlled by the Hall sensor-less circuit is greater than 80000 rotations per minute.
  • the present application further includes the following subordinate technical solutions.
  • the Hall sensor-less circuit adopts an analog electronic circuit to detect a counter electromotive force of the motor, and the counter electromotive force acts as a feedback signal for a rotor magnetic pole position.
  • the motor further includes: an iron core with a central circle, a rotor running through the central circle, a first end cap for fixing one end of the iron core, a second end cap mating with the first end cap and fixing another end of the iron core, a movable impeller located at one side of the second end cap and driven by the rotor, an impeller cover receiving the movable impeller and fixed on the second end cap, a fixed impeller located between the second end cap and the movable impeller, and a circuit board located outside of the first end cover and provided with a Hall sensor-less circuit.
  • an iron core with a central circle, a rotor running through the central circle, a first end cap for fixing one end of the iron core, a second end cap mating with the first end cap and fixing another end of the iron core, a movable impeller located at one side of the second end cap and driven by the rotor, an impeller cover receiving the movable impeller and fixed on the second end cap, a fixed impeller located between the second
  • a high-speed Hall sensor-less three-phase vacuum cleaner motor includes: an iron core with a central circle, a rotor running through the central circle, a first end cap for fixing one end of the iron core, a second end cap mating with the first end cap and fixing the other end of the iron core, a movable impeller located at one side of the second end cap and driven by the rotor, an impeller cover receiving the movable impeller and fixed on the second end cap, a fixed impeller located between the second end cap and the movable impeller, and a circuit board located outside of the first end cover.
  • the circuit board is provided with a Hall sensor-less circuit cooled by wind outputted by the motor and a rotational speed of the motor controlled by the Hall sensor-less circuit is higher than 80000 rotations per minute.
  • the present application further includes the following subordinate technical solutions.
  • the iron core includes a circular iron core outer edge and a plurality of protrusions formed by an inner wall of the iron core outer edge radially extending to the center.
  • a pole shoe is provided at one end near the center of each protrusion, and a pole shoe angle a of each pole shoe is within the scope of 90 to 100 degrees.
  • arcs of the pole shoes are in the same center circle, and a diameter of the center circle ranges from 10 to 15 millimeter.
  • a unilateral air gap between each pole shoe and the rotor is 0.5 millimeter.
  • an outer wall of the iron core outer edge protrudes outwards to form a plurality of flanges.
  • the flanges are corresponding to the respective protrusions, and are each provided with a location hole and a screw hole next to the location hole. Centers of the location hole and the screw are in the same circle.
  • the first end cap includes end cap outer edge, a supporting portion connected to the end cap outer edge, and multiple cooling gaps between the end cap outer edge and the supporting portion.
  • the supporting portion includes a center having an axle hole and a plurality of supporting arms. Each supporting arm has one end connected to the center and another end connected to the end cap outer edge.
  • the cooling gaps are at least partially aligned to arc-shaped gaps in the axial direction.
  • the circuit board includes a plurality of MOS tubes located in the cooling gaps.
  • the Hall sensor-less circuit comprises: a controller, a power supply unit that provides power to the controller, a pre-drive unit connected to an output end of the controller, a three-phase bridge power circuit unit connected to an output end of the pre-drive unit and the motor, and a current sampling unit arranged between the controller and the three-phase bridge power circuit unit.
  • the present application has the following advantages.
  • the high-speed Hall sensor-less three-phase vacuum cleaner motor also has advantages such as a high rotational speed, a small size, a high performance, being convenient to carry, energy-saving, a long service life and so on. Thus a super-high dust collection performance may be achieved if the motor is applied to a vacuum cleaner.
  • FIG. 1 is an exploded view of a high-speed Hall sensor-less three-phase vacuum cleaner motor according to the present application
  • FIG. 2 is a sectional view of an assembled high-speed Hall sensor-less three-phase vacuum cleaner motor according to the present application
  • FIG. 3 is a top view of an iron core of the high-speed Hall sensor-less three-phase vacuum cleaner motor according to the present application
  • FIG. 4 is a perspective view of an iron core of a high-speed Hall sensor-less three-phase vacuum cleaner motor according to the present application in another view, in which a circuit board is removed;
  • FIG. 5 is a perspective view of an iron core of a high-speed Hall sensor-less three-phase vacuum cleaner motor according to the present application
  • FIG. 6 is a perspective view of a circuit board according to the present application.
  • FIG. 7 is a schematic circuit diagram of a Hall sensor-less circuit according to the present application.
  • FIG. 8 is an experimental data graph when a pole shoe angle of the iron core according to the present application is 85 degrees;
  • FIG. 9 is an experimental data graph when a pole shoe angle of the iron core according to the present application is 92 degrees;
  • FIG. 10 is an experimental data graph when a pole shoe angle of the iron core according to the present application is 98 degrees.
  • FIG. 11 is an experimental data graph when a pole shoe angle of the iron core according to the present application is 105 degrees.
  • a high-speed Hall sensor-less three-phase vacuum cleaner motor is provided according to an embodiment of the present application.
  • the motor is a brushless direct-current motor.
  • the motor includes: an iron core 1 with a central circle 18 , a rotor 2 running through the central circle 18 , a first end cap 3 for fixing one end of the iron core 1 , a second end cap 4 mating with the first end cap 3 and fixing the other end of the iron core 1 , a movable impeller 5 located at one side of the second end cap 4 and driven by the rotor 2 , an impeller cover 7 receiving the movable impeller 5 and fixed on the second end cap 4 , a fixed impeller 8 located between the second end cap 4 and the movable impeller 5 , and a circuit board 6 located outside of the first end cover 3 .
  • the circuit board 6 is provided with a Hall sensor-less circuit cooled by wind outputted by the motor and the rotational speed of the motor controlled by the Hall sensor-less circuit is higher than 80000 rotations per minute.
  • the diameter of the center circle ranges from 10 to 15 millimeters.
  • a unilateral air gap between each pole shoe and the rotor 2 is 0.5 millimeter.
  • the iron core 1 includes a circular iron core outer edge 10 , a plurality of protrusions 12 formed by an inner wall of the iron core outer edge 10 extending radially to the center, and a plurality of flanges 14 formed by an outer wall of the iron core outer edge 10 protruding outwards.
  • a pole shoe 120 is provided at one end of each protrusion 12 , and an angle of each pole shoe 120 is within the scope of 90-100 degrees.
  • the arc of each pole shoe 120 is in the same center circle 18 to decrease the commutation loss of electronic elements.
  • An arc-shaped gap 16 is formed between two adjacent protrusions 12 .
  • the flange 14 is provided with a screw hole 140 and a location hole 142 adjacent to the screw hole 140 , and circle centers of the screw hole 140 and the location hole 142 are in the same circle.
  • the number of the protrusions 12 is preferably 3, and an angle between central points of two adjacent protrusions 12 in circumferential direction is 120 degrees.
  • the number of flanges 14 is preferably 3, and the central line of the flange 14 and the central line of the corresponding protrusion 12 are in the same straight line.
  • the screw hole 140 and the location hole 142 are used for installation and positioning of the iron core.
  • the screw hole 140 is independent from a magnetic circuit of the iron core, thus it may not adversely affect the magnetic circuit and loss of the iron core.
  • the first end cap 3 includes: a circular end cap outer edge 30 , a supporting portion 32 connected to the end cap outer edge 30 , and a plurality of cooling gaps 34 located between the end cap outer edge 30 and the supporting portion 32 .
  • the supporting portion 32 includes a center 320 having an axle hole 322 and a plurality of supporting arms 324 . One end of each supporting arm 324 is connected to the center 320 and the other end of the supporting arm 324 is connected to the end cap outer edge 30 .
  • the rotor 2 is allowed to pass through the axle hole 322 .
  • a cooling gap 334 is formed between two adjacent supporting arms 324 .
  • Each supporting arm 324 is provided with a circuit board screw hole 326 and an end cap screw hole 322 .
  • the screw hole 140 and the end cap screw hole 322 are in the same direction to achieve fixed connection of the first end cap 3 , the second end cap 4 and the iron core 1 through a long screw.
  • the number of the supporting arms 324 is preferably 3. And an axial direction of the supporting arm 324 is substantially corresponding to the protrusion 12 of the iron core 1 .
  • the cooling gap 34 is an air outlet of the motor, and the cooling gap 34 is aligned to the arc-shaped gap 16 in the axial direction, thus preventing the case that the cooling air, due to being blocked by the supporting arm, cannot blow to a MOS tube on the circuit board 6 to adversely affect the heat dissipation.
  • the structure is simple and the size of the motor is reduced without increasing the cost.
  • a circuit board 6 includes: a plurality of MOS tubes 60 arranged in the cooling gaps 34 , one or more cooling fins 62 covering the MOS tubes 60 , and a screw 64 that is fixed to the end cap screw hole 322 and used for fixing the circuit board 6 on the first end cap 3 .
  • heating elements such as the MOS tube are arranged at the air outlet of the motor for cooling, and the cooling fin with a thickness of 2 millimeters is provided on the MOS tube for better cooling.
  • a Hall sensor-less circuit is also called a motor control circuit.
  • an analog electronic control circuit to detect a counter electromotive force of the motor and adopting the counter electromotive force, instead of signal of the Hall sensor, as a feedback signal for a magnetic position of the rotor, a motor with a Hall sensor-less structure is achieved.
  • the Hall sensor-less circuit includes: a controller 510 , a power supply unit 520 that provides power to the controller 510 , a pre-drive unit 520 connected to an output end of the controller 510 , a three-phase bridge power circuit unit 530 that connected to an output end of the pre-drive unit 520 and a motor BLDC, a current sampling unit 511 arranged between the controller 510 and the three-phase bridge power circuit unit 530 , a voltage sampling unit 512 bi-directionally connected to the controller 510 , a speed control unit 514 bi-directionally connected to the controller 510 , a motor control unit 516 bi-directionally connected to the controller 510 , and a temperature sampling unit 516 bi-directionally connected to the controller 510 .
  • the three-phase bridge power circuit unit 530 includes multiple MOS tubes 60 .
  • the power supply unit 520 provides power to the pre-drive unit 520 and the three-phase bridge power circuit unit 530 respectively, with an input direct-current voltage being 21.6V.
  • the pre-drive unit 520 converts PWM signals outputted by the controller 510 into signals which have enough drive capability and are suitable for driving a three-phase bridge.
  • the three-phase bridge power circuit unit 530 is a power converting unit controlled by the pre-drive unit 520 , and is used for driving the motor BLDC to operate normally.
  • the controller 510 receives UI input circuit signals (such as speed adjusting control, start-stop control), detects working environment (such as working current, working voltage, ambient temperature), and outputs suitable PWM control signals according to UI input and environment input conditions.
  • the current sampling unit 511 detects the working current of the whole circuit in real-time to realize over-current protection and load short-circuit protection.
  • the voltage sampling unit 512 detects the working voltage of the whole circuit in real-time to realize over-voltage/under-voltage protection.
  • the speed control unit 514 is a UI control circuit for controlling the motor to operate in a high-speed or low-speed mode.
  • the motor control unit 516 is a UI control circuit for controlling the motor to start or stop.
  • the temperature sampling unit 516 detects ambient working temperature in real-time to realize temperature protection.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Brushless Motors (AREA)
  • Control Of Motors That Do Not Use Commutators (AREA)
  • Motor Or Generator Cooling System (AREA)
  • Electric Suction Cleaners (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
US15/575,985 2015-07-16 2015-12-16 High-speed hall sensor-less three-phase vacuum cleaner motor Abandoned US20180152077A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
CN201510416438.2 2015-07-16
CN201510416438.2A CN104967253B (zh) 2015-07-16 2015-07-16 高速无霍尔三相吸尘器电机
PCT/CN2015/097549 WO2017008439A1 (zh) 2015-07-16 2015-12-16 高速无霍尔三相吸尘器电机

Publications (1)

Publication Number Publication Date
US20180152077A1 true US20180152077A1 (en) 2018-05-31

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Application Number Title Priority Date Filing Date
US15/575,985 Abandoned US20180152077A1 (en) 2015-07-16 2015-12-16 High-speed hall sensor-less three-phase vacuum cleaner motor

Country Status (7)

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US (1) US20180152077A1 (ja)
EP (1) EP3324520B1 (ja)
JP (1) JP2018521614A (ja)
CN (1) CN104967253B (ja)
AU (1) AU2015402113B2 (ja)
CA (1) CA2984821C (ja)
WO (1) WO2017008439A1 (ja)

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EP3324520A1 (en) 2018-05-23
JP2018521614A (ja) 2018-08-02
EP3324520A4 (en) 2019-04-03
CA2984821C (en) 2021-11-02
CA2984821A1 (en) 2017-01-19
AU2015402113A1 (en) 2017-11-23
WO2017008439A1 (zh) 2017-01-19
AU2015402113B2 (en) 2019-09-12

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